Clutch Slave Cylinder: Service and Repair

Slave cylinder, removing and installing, 01A, 5 SPD. M/T (AWD)

Special tools, testers and auxiliary items required

Torque wrench V.A.G. 1331:

^ Lithium grease G 052 150 A2
^ Copper grease Z 381351 TE

Removing
^ Remove sound insulation beneath transmission.
^ Remove front exhaust pipe with catalytic converter if necessary.





^ Remove bolt - arrow -, pull out slave cylinder toward rear.
Do not press clutch pedal after clutch slave cylinder has been removed.





^ To remove hose/line assembly, clip - A - must be pried out until stop using a screwdriver. Only after that can hose/line assembly be disconnected.
Brake fluid must not penetrate into transmission. If necessary, clean transmission housing.

Installing
Installation is in reverse order of removal. Note the following:
^ Brake fluid must not penetrate into transmission. If necessary, clean transmission housing.
^ Replace mounting bolt for slave cylinder.
^ Coat contact surface for plunger on clutch release lever thinly with copper grease Z 381351 TE.





^ Before installing clutch slave cylinder into transmission housing, coat boot area - a - with lithium grease G 052 150 A2.





^ Engage bracket - 3 -for hose/line assembly - 1 - on slave cylinder - 4 -.





^ Guide slave cylinder - 1 - as far as possible into mounting hole of transmission housing without deviation sideways from working direction of plunger - arrow A -.
^ While doing this, insert into recess - arrow B - of clutch release lever - 3

Then screw in a new socket head bolt - 2 - on transmission. To do so, push slave cylinder far enough until socket head bolt can be installed.

If slave cylinder - 1 - is guided in while canted, there is the risk that plunger - arrow A - will bypass at the clutch release lever - 3

CAUTION:
Operate clutch pedal carefully after installing slave cylinder.

If clutch pedal exhibits an unusually heavy pressure point when being operated, do not operate clutch pedal any further.

Slave cylinder plunger was guided past at clutch release lever.

From a pedal pressure of approximately 300 N, slave cylinder is then destroyed.

For comparison: Normal pedal pressure is approximately 115 N.





^ Tighten bolt - arrow - to tightening torque.





^ To connect hose/line assembly - B - to slave cylinder, clips - A - must be pressed in to stop.
^ Insert hose/line assembly - B - in slave cylinder until line engages audibly.
^ To check, pull on hose/line assembly.
^ Bleed clutch system.
^ If removed, install front exhaust pipe with catalytic converter and align exhaust system free of tension.
^ Install sound insulation beneath transmission.